Surge Suppression Applictation Notes 2013

Eatons guide to
surge suppression
Applications notes
Contents
Description Page
Summary of applicable UL and IEEE standards

for surge protection devices ........................................................ 4
High-resistance grounding and wye or delta
surge protection devices .............................................................. 9
Surge current per phase (industry definition) .................................. 10
Facility-wide surge suppression ...................................................... 10
Debunking the surge current myth,
Why excessive surge current ratings are not required ............ 11
Surge arrestor vs. surge suppressor ............................................... 12
Benefits of hybrid filtering in surge protection devices .................. 14
Factory automation (PLCs) and their need for
surge suppression ........................................................................ 16
Surge protection devices with replaceable modules ...................... 17
Why silicon avalanche diodes are not recommended
for AC powerline suppressors ..................................................... 18
Surge protective device frequently asked questions ...................... 20
2 EATON CORPORATION Eatons guide to surge suppression

Why Eaton? provide protection for all For information on
connected electronic loads. Eatons Powerware SPD
As a premier diversified
This design provides superior product line, please visit
industrial manufacturer, Eaton
suppression ratings and elimi- www.powerware.com/tvss.
Corporation meets your electri-
nates poor performance that
cal challenges with advanced
result from poor cable Innovative Technology
electrical control and power
connections and long lead
distribution products, industrial Since 1980, Innovative
lengths. Integrated transient
automation, world-class manu- Technology products have
voltage surge suppression
facturing, and global engineering solved the most difficult elec-
(TVSS) is the number one choice
services and support. trical transient problems for
for surge suppression in new-
Customer-driven solutions come business, industry, government
construction applications.
in the form of industry-preferred and defense sectors. Innovative
product brands such as Cutler- In addition to the extensive Technology products and
Hammer, MEM, Holec, integrated SPD offering, the Technologies protect electrical,
Powerware and Innovative Cutler-Hammer SPD product data, telecom circuits, and
Technology. line includes a wide variety of electronic equipment from the
Eaton has an extensive fam- surge current ratings, monitoring effects of lightning-induced
ily of surge protective devices features and external enclosure voltages, external switching
(SPD) for any facility or applica- options. The Cutler-Hammer transients, and internally gener-
tion. Using our Cutler-Hammer, SPDs are available from autho- ated electrical transients.
Powerware and Innovative rized Cutler-Hammer electrical
wholesalers. For information As a part of Eatons electrical
Technology branded products business since 2003, Innovative
will ensure that the quality of on Eatons Cutler-Hammer SPD
product line, please visit Technology SPD products are
power required to maximize even better positioned to deliver
productivity in todays competi- www.eaton.com/tvss.
state-of-the-art customer solu-
tive environment will be tions. Innovative Technology
supplied in the most reliable, Powerware products are designed to be the
safe and cost-effective manner. Lightning and other transient most rugged and durable SPDs
Eaton has developed specific voltage and current-producing in the market. Based on exten-
surge protection solutions for phenomena are harmful to sive proven field performance,
commercial, industrial, insti- most UPS equipment and Innovative Technology was
tutional, telecommunication, electronic load equipment the first to offer a 20-year full
military, medical and residential connected to the UPS. For replacement warranty. Electrical
applicationsboth for North example, the transient may engineers around the world
America and throughout reach the critical load via an recognize Innovative Technology
the world. unwanted activation of an as a leader in the SPD industry.
unprotected static-switch A leading research company in
bypass path around a UPS. a survey of over 10,000 users
Cutler-Hammer
Therefore, it is recommended rated Innovative Technology
Eatons Cutler-Hammer SPDs practice that both the input number one in both product
are designed to be fully inte- circuit to the UPS and the quality and service.
grated into new switchgear associated UPS bypass cir- Innovative Technology SPD
and new panels for the closest cuits (including the manual products are available in a wide
possible electrical connection. maintenance bypass circuit) range of voltages (including volt-
When installing a surge suppres- be equipped with effective ages up to 5 kV), surge current
sor, it is important to mount it as Category B surge protective ratings, monitoring features and
close to the electrical equipment device, as specified in IEEE Std. enclosure options.
as possible in order to keep the C62.41-1991. Low-inductance
wiring (lead length) between connections should be For information on Eatons
the electrical equipment and the employed for this protection. Innovative Technology products,
suppressor as short as possible. please visit www.itvss.com.
As such, Eaton was the first Eaton's Powerware surge
to introduce the Direct-On protective devices can be fully
bus bar connected SPD that integrated into power distri-
provides customers with the bution units (PDUs), and are
lowest system let-through designed to meet the
voltage at the bus bar when demanding needs of the same
compared to traditional cable mission-critical applications and
connected surge protectors. By facilities that utilize Powerware
utilizing a direct bus bar con- uninterruptible power systems
nection, Cutler-Hammer SPDs (UPS). Powerware surge protec-
achieve the industrys lowest tion devices are available in a
let-through voltage to effectively wide variety of surge current
suppress both high and low ratings, monitoring features and
energy transient events and enclosure options.
Source: IEEE RDP Std. 1100-1999.
EATON CORPORATION Eatons guide to surge suppression 3

Summary of applicable UL and IEEE standards for surge protection devices
TABLE 1. STANDARD DESCRIPTIONS
Standard
(Current revision date) Purpose of standard/comments
UL 1449 (1987) 1. Safety test (constructed of approved components in a safe manner).

Transient voltage surge suppressors 2. Suppressed voltage rating (let-through voltage using the IEEE C62.41 C1 test wave).
(TVSS)
Other IEEE recommended waveforms such as the C3 and B3 Ringwave are not tested by UL.
UL 1449 (2nd Edition 1996) 1. Additional safety tests. Test for other standards used to improve safety of products.
2. Surge test. Let-through voltage tested at lower current than 1st Edition.
10 kA (IEEE Cat. C3) used for the first time; however, it was used only to see if products fail safely.
UL 1449 (2nd Edition 2007) 1. Stringent new safety requirements. New tests subject TVSS units to prolonged AC overvoltage
conditions to ensure safe failure modes
2. UL label changes to the wording of the short circuit current rating.
3. New Testing at 10, 100, 500 and 1000A and system voltage were added to ensure the units
fail in a safe manner.
UL 1449 (3rd Edition 2009) 1. TVSS will now be referred to as SPD (surge protective devices).
2. UL 1449 is now ANSI/UL 1449.
3. Addition of four types of SPDs to cover surge arrestors, TVSS, surge strips and component SPDs.
UL 1283 (1996) This safety standard covers EMI filters connected to 600V or lower circuits. The UL 1283 is a safety stan-
Electromagnetic interference filters dard and does not include performance tests such as MIL-STD-220A insertion loss or Cat. B3 Ringwave
let-through voltage tests.
UL 497, 497A, 497B Safety standard for primary telephone line protectors, isolated signal loops and surge protection used on
communication/data lines. No performance tests conducted for data/communication lines.
IEEE C62.41.1 (2002) IEEE Guide on the Surge Environment in Low-Voltage AC Power Circuits. This is a guide describing the
surge voltage, surge current, and temporary overvoltages (TOV) environment in low-voltage [up to
1000V root mean square (Rms)] AC power circuits.
IEEE C62.41.2 (2002) IEEE-recommended practice on characterization of surges in low-voltage AC power circuits.
This document defines the test waves for SPDs.
IEEE C62.45 (2002) Guide on surge testing for low voltage equipment (ANSI). This document describes the test
methodology for testing SPDs.
IEEE Emerald Book Reference manual for the operation of electronic loads (includes grounding, power requirements, and so on).
NEMAT LS-1 NEMA Technical Committee guide for the specification of surge protection devices including physical and
operating parameters.
NECT National Electrical Code Articles 245, 680 and 800.
NFPAT 780 Lightning protection code recommendations for the use of surge protection devices at a facility
service entrance.
UL 1449 does not require a maximum surge current test.
Underwriter laboratories electrical distribution system Notes

UL 1449 (Revision 7-2-87), (i.e., UL 1449 does not include UL 1449 Second Edition does
Transient voltage surge the effects of installation lead not test a suppressor to other
suppressors (TVSS) length and overcurrent protec- important test waveforms such
tion). A duty cycle test is based as the IEEE Cat. C3 service
UL 1449 is the standard for
on a 26-shot withstand test. The entrance surge (20 kV, 10 kA)
all equipment installed on the
UL test uses waveforms similar or the B3 Ringwave (6 kV, 100
load side of the AC electrical
to those recommended in IEEE kHz), the most common type of
service and throughout the facil-
62.41. To pass UL 1449, the transient inside a facility.
ity for AC distribution systems.
TVSS unit must withstand the
This includes both hardwire UL does not verify the TVSS
duty cycle test and not degrade
and plug-in products. To obtain device will achieve the
by more than 10% from its initial
a UL listing, the suppressor manufacturers published surge
let-through voltage value.
must meet the required safety current ratings. NEMA LS-1
standards and pass a duty cycle All UL-listed TVSS equipment provides the guidelines for
test. In addition, UL conducts a displays the SVR rating for each product specification.
let-through voltage test on the applicable protection mode.
suppressor and assigns a sup- If this rating is not affixed to the Plug-in products are tested
pressed voltage rating (SVR). TVSS, then one must assume differently and cannot be
UL 1449 ratings represent a the device is not UL 1449 listed. compared to hardwired devices.
component rating and not the
actual let-through voltage of the

UL 1449 (1996 and 2007 The measured limiting voltage In addition to successfully UL 1449 (2009 3rd Edition) UL
2nd Edition) test is used to assign each TVSS passing all applicable tests, all 1449 3rd Edition is now ANSI/
a suppressed voltage rating UL-listed TVSS units must be UL 1449. The change in desig-
Underwriters Laboratories
(SVR), which appears on all UL suitably and plainly marked. nation helps the standard gain
standard for safety for transient
certified units. This rating takes These markings include name of relevance in North America and
voltage surge suppressors (UL
the average let-through voltages the manufacturer, a distinctive brings it closer to the IEC stan-
1449) is the primary safety stan-
of three 6000V, 500A combina- catalog number, the electrical dards. By becoming a national
dard for transient voltage surge
tion wave impulses (IEEE 62.41 rating, short circuit current rat- standard and forming a voting
suppressors (TVSS). This stan-
cat C1 test waves) and rounds ing (SCCR), SVR, and the date committee, the standard also
dard covers all TVSS products
up to the next highest stan- or period of manufacture. The ensures conformance to NAFTA.
operating at 50 or 60 Hz, at volt-
dard SVR class set by UL. The TVSS must also be marked with This revision changes the des-
ages 600V and below.
standard SVR classes are 330, the words transient voltage ignation of the TVSS devices,
The UL 1449 safety standard 400, 500, 600, 800, 1000, 1200, surge suppressor or TVSS, from TVSS to Type 2 surge
was first published in August of 1500, 2000, 2500, 3000, 4000, and is able to be additionally protective devices (SPDs). The
1985. As TVSS products have 5000 and 6000V. For example, marked immediately following SPD is used as an umbrella des-
evolved in the marketplace, the a 401V average let-through volt- in parentheses with the words ignation and includes all types of
standard has been updated to age is rounded up to a 500V (surge protective device) surge protective products. The
ensure the continued safety of SVR. The test is conducted with or (SPD). type designation of the SPD
the increasing sizes, options six inches of lead length, (length will be determined based on the
The best way to verify that par-
and performance of new TVSS of wire from TVSS to test installation location within an
ticular TVSS unit is UL listed is
designs. The second edition equipment connection point). electrical system. Some exam-
to conduct a search on the UL
of UL 1449 was published in Let-through voltages are signifi- ples are surge arrestors (Type
Web site at www.ul.com. The
1996. The second edition of the cantly affected by lead length. 1 SPD), cord connected TVSS
certification category for TVSS
UL 1449 TVSS standard was Therefore, a six-inch lead length (Type 3 SPD) and a new cat-
is UL category code XUHT.
revised in February 2005 and is used to standardize the test. egory of component SPD (Type
An alternate way to verify a
required compliance by February The SVR value allows some 4 SPD). The last nomenclature
vendors listing is to call UL at
9, 2007. All TVSS products comparison from one TVSS to modification is the change of
1-847-272-8800. A listed prod-
manufactured after February another, but does not represent SVR (suppressed voltage rat-
uct provides a user with the
9, 2007 must comply with the an expected field installed let- ing) to VPL (voltage protection
confidence their TVSS unit will
February update to the standard. through voltage since actual level). The new VPL ratings are
not create a shock or fire hazard
A third edition of UL 1449 was installed lead length will vary required to be displayed on the
during use.
published in September of 2006 from installation to installation. UL tags for the each SPD unit.
with compliance required by
The last major series of tests are UL 1283 electromagnetic The revised standard includes
October of 2009. This article
the abnormal overvoltage tests. interference filters some testing modifications
relates to the latest revision of
The purpose of these tests is to that include tests for nominal
the second edition of UL 1449, Surge suppressors must be
ensure that the TVSS will discharge current, tests to deter-
which is currently in effect and listed (or recognized) under UL
not create a shock or fire hazard, mine VPL and measured limiting
is acceptable until October 1449. Those devices employing
even if the unit is misapplied voltage at 6 kV/3 kA.
of 2009. an EMI filter can also be compli-
or subjected to a sustained
To obtain a UL listing, a suppres- overvoltage event. TVSS are mentary listed under UL 1283 to
sor must pass a series of tests designed to prevent high ener- ensure the filter components are
designed to ensure it does not gy, short duration (typically two properly designed to withstand
create any shock or fire hazards milliseconds or less) transient the required duty cycle and
throughout its useful life. Each voltages from causing damage stress requirements. UL 1283
TVSS product is subjected to the to an electrical installation. TVSS covers EMI filters installed on,
following electrical and mechani- are not designed to sustain or connected to, 600V or lower
cal tests: leakage current, long-term overvoltages. During circuits. These filters consist of
temperature, ground continuity, the abnormal overvoltage test, capacitors and inductors used
enclosure impact, adequacy of the TVSS unit is subjected to a alone or in combination with
mounting, and many others. voltage higher than its normal each other. Included under this
Each test evaluates a differ- operating voltage, typically near requirement are facility filters,
ent function or potential failure double the design voltage. The hardwired and plug-in devices.
mode of a TVSS. To obtain UL overvoltage test is performed UL 1283 reviews all internal
certification, the TVSS unit must with current limited to the fol- components and enclosures,
pass all tests. Two of the most lowing current levels: 10, 100, insulating material, flamma-
significant tests performed on 500 and 1000A. Every mode of bility characteristics, wiring
a TVSS are the measured limit- the TVSS is subjected to the and spacing, leakage current,
ing voltage test and a series of abnormal overvoltage tests. temperature ratings, dielectric
abnormal overvoltage tests. The testing of each mode is withstand and overload char-
sustained for up to seven hours. acteristics. UL 1283 does not
During this time, the TVSS can- include performance tests such
not create a fire or shock hazard. as the MIL-STD-220A insertion
loss test to determine the dB
rating of the filter at the desired
frequency (i.e., 100 kHz for hard-
wired AC power systems) or the
let-through voltage test using
the IEEE Cat. B3 Ringwave.

Data/communication line ANSI/IEEE C62.41 (2002) 8000
protectors (UL 497, recommended practice on
497A, 497B) surge voltages in low voltage 6000
AC power circuits (ANSI)
UL 497 is the safety standard for
single or multi-pair Telco primary This document describes a typi- 4000
protectors. Every telephone line cal surge environment based on
provided by a telephone opera- location within a facility, power- 2000
tor must have an UL-approved line impedance to the surge and
T1 protector (gas tube or car- total wire length. Other param-
0
bon arrestor) in accordance eters include proximity, type of
with Article 800 of the National electrical loads, wiring quality
Electric Code (NEC). and geographic location. 2000
A primary protector is required The document only describes

4000
to protect equipment and typical surge environments and 10 0 10 20 30 40
personnel from the excessive does not specify a performance
potential or current in telephone test. The waveforms included FIGURE 2. RINGWAVE
lines caused by lightning, in the document are meant as
contact with power conductors standardized waveforms that The amplitude and available The Category C surges can
and rises in ground potential. can be used to test protective energy of the standard wave- enter the building at the service
UL 497A applies to secondary equipment. Any statement forms are dependent upon entrance. SPDs must be sized to
protectors for communication where a manufacturer advertis- location within a facility. withstand these types of surges
circuits. Secondary protectors es that its protector meets the As shown in Figure 3, when installed at switchgear or
are intended to be used on the requirement of, or is certified locations are classified into service entrance switchboard.
protected side of telecommu- to IEEE C62.41," is inappropriate three categories: The second variable used to
nication networks (it assumes and misleading. classify the environment of a
primary protectors are in place) power disturbance is exposure.
Two selected voltage/current Category A: outlets and long
that have operating Rms voltage As shown in Figure 4, IEEE
waveforms (see Figures 1 branch circuits
to ground less than 150V. These has defines three exposure
and 2) are identified as
protectors are typically used at All outlets at more that 10m levels that characterize the rate
representative of typical
the facility incoming service or (30 ft) from Category B of surge occurrence versus
electrical environments:
other areas where communica- voltage level at an unprotected
1. Combination wave: a unipolar All outlets at more than 20m
tion circuits require protection. site. The three exposure
pulse that occurs most often (60 ft) from Category C
UL 497B applies to data com- categories include:
munication and fire alarm circuit outside a facility (e.g., a
Category B: feeders and short Low exposure: applications
protectors (communication alarm lightning strike)
branch circuits known for low lightning
initiating or alarm indicating loop 2. 100 kHz Ringwave: an activity, little load switching
circuits). This includes most oscillating waveform that Distribution panel devices
dataline protectors in the Medium exposure: systems
occurs most often inside Bus and feeder distribution
electrical industry. and geographical areas known
a facility
Heavy appliance outlets with for medium to high lightning
short connections to activity or with significant
service entrance switching transients or both
10,000 High exposure: those rare
Lighting systems in
large buildings installations that have greater
surge exposure than those
8000 defined as low or medium
Category C: outside and
service entrances
6000 Service drops from pole
to building
Runs between meter
4000 and panel
Overhead lines to
2000
detached building
Underground lines to
well pump
0
0 10 20 30 40
FIGURE 1. COMBINATION WAVE

Category A Category B Category C
Long branch circuits Major feeders Outdoor overhead lines
Indoor receptacle Short branch circuits Service entrance
Indoor service panels
FIGURE 3. IEEE C62.41 LOCATION CATEGORIES
Isokeraunic maps provide a good Number of surges per year

baseline for evaluating lightning exceeding surge crest of abscissa
occurrence within a region.
Discussions with local utilities 10
and other major power users
combined with power quality High
exposure
surveys are useful for measuring
the likely occurrences from load
switching and power factor
correction capacitors. 10
For each category and exposure
level, IEEE has defined the test
waveform that should be used
Medium
by a specifier when determining exposure
performance requirements. For
10
example, most SPDs installed
at the main service panel after
the meter are in a Category C
environment. Table 2 details the
C62.41 test waveforms for
categories A, B and C.
1
In the C62.41 (2002) document,
special waveforms have been
identified to address large banks
of switching capacitors or the
Sparkover
operation of fuses at the end clearances
of long cables. These situations
10
warrant the consideration of
additional waveforms where
energy is greater than those
stipulated for Category A, B and
C environments. Low
Many specifiers are confused exposure
about the recommendations 10
contained in C62.41. Often the 0.5 1 2 5 10 20
document is misapplied because
category environments and test Surge crest kV
waveforms are used as perfor-
FIGURE 4. COMBINATION WAVE
mance standards (e.g., ability
to meet C62.41).
The C62.41 recommendations
should be used for selecting spec-
ifications appropriate to the needs
of a given designer or end user.

IEEE C62.45 (2002)Guide on IEEE Std. 1100 (2005) Emerald NEMA LS-1 Article 285 covers the gen-
Surge Testing for Equipment Book Recommended Practice eral requirements, installation
This document is a specifica-
Conducted to Low Voltage AC for Powering and Grounding requirements, and connection
tion guide for surge protection
Power Circuits Sensitive Electronic requirements for transient
devices for low voltage AC
Equipment voltage surge suppressors
This document provides power applications (less than
permanently installed on
appropriate surge testing guide- This publication presents recom- 1000V). The document identifies
premise wiring systems.
lines for equipment survivability, mended engineering principles key parameters and evaluation
methods of test connection, and practices for powering and procedures for specifications. Article 645 covers electronic
surge coupling mode definitions, grounding sensitive electronic NEMA employed established computer/data processing
testing safety requirements equipment. This standard is the references such as IEEE and Equipment and references
and various theories of surge recommended reference book UL guidelines. The following National Fire Protection
suppression techniques. The for facility-wide power quality parameters are included in Association (NFPA) 75.6.4
intent is to provide background solutions. The scope of this the LS-1 document: regarding the protection of
information that can help publication is to recommend electronic computer/data
Maximum continuous
determine if specific equipment design, installation and main- processing equipment.
operating voltage (MCOV)
or a circuit has adequate tenance practices for electrical Article 800 reviews protection
withstand capability. power and grounding of sensi- Modes of protection
requirements (800-31),
An important objective of the tive electronic processing Maximum surge current secondary protector require-
document is to call attention to equipment used in commercial per mode ments (800-32) and cable and
the safety aspects of surge and industrial applications. protector grounding (800-40)
The following sections apply to Clamping voltage (A3, B3
testing. Signal and datalines Ringwave, B3/C1 impulse, for communication circuits.
are not addressed. surge protection devices:
C3 impulse)
Chapter 3 (particularly 3.4.2 National Fire Protection
and 3.4.3) EMI noise rejection Association (NFPA)780
(insertion loss) lightning-protection code
Chapter 4 (particularly 4.2
and 4.4) Safety UL approvals (including
NFPA 780 is the code for
UL 1449, UL 1283)
Chapter 8 (particularly 7.2) lightning protection systems
Application environment and addresses the protection
Chapter 9 (particularly 8.6) requirements for ordinary
NEMA LS-1 (and other organiza-
tions) do not recommend the structures, miscellaneous
TABLE 2. IEEE C62.41 CURRENT/VOLTAGE WAVEFORMS FOR use of Joule ratings or response structures and special occu-
VARIOUS EXPOSURE LOCATIONS pancies, industrial operating
time as a performance criteria
1.2 X 5S (V) for SPDs. environments, and so forth. The
0.5S X 100 KHZ 8 X 20S (A) following paragraphs are related
VOLTAGE RING WAVE COMBINATION WAVE
CAT. LEVEL (KV) CURRENT (A) CURRENT (KA) to surge protection: 3-21 surge
National Electrical Code
suppression. Devices suitable
A1 Low 2 70 (United States): NECarticle
for protection of the structure
A2 Medium 3 130 280, 285, 645 and 800
shall be installed on electric and
surge arrestors
A3 High 6 200 telephone service entrances,
The adequacy section of the and on radio and television
B1 Low 2 170 1
code clearly states that antenna lead-ins.
B2 Medium 4 330 2 compliance with the code will
B3 High 6 500 3 Note: Electrical systems and
not ensure the proper equip- utilization equipment within the
C1 Low 6 3 ment performance. This fact structure may require further
C2 Medium 10 5
is often overlooked by end surge suppression.
users/customers considering Shall indicate a mandatory
C3 High 20 10 electrical designs from a low- requirement.
bid perspective.
Article 280 covers the gen-
eral requirements, installation
requirements and connection
requirements for surge arrestors
installed on premises
wiring systems.

High-resistance grounding In todays electrical systems, A B
and wye or delta surge with many different grounding
protection devices systems and various voltages,
determining which SPD voltage
In todays manufacturing
configuration to specify can be
facilities, ground faults can
confusing. Following are sev-
wreak havoc on production and
eral helpful guidelines to follow
process equipment. These man-
when specifying SPDs:
ufacturing facilities may have a
high-resistance grounding (HRG) Only apply a wye (three-
system. In an HRG system, a phase, four-wire) configured
resistance, which is connected SPD if the neutral is physically R
between the neutral of the connected to the SPD and
transformer secondary and earth if the neutral is directly and
ground, is used that effectively solidly bonded to ground
limits the fault current to a low Use a delta (three-phase, C
value current under ground fault three-wire) configured SPD
conditions. Usually, the current for any type of impedance
is limited to 10A or less. As a (resistive, inductive) grounded Ground
result, the system will continue system
to operate normally, even under FIGURE 5. RESISTANCE GROUNDING SCHEME
the ground fault condition. Use a delta (three-phase,

three-wire) configured SPD
Figure 5 depicts a system for a solidly grounded wye A
that has a resistance ground- system where the neutral
ing scheme. In the case where wire is not pulled through to
surge suppression is required the SPD location B
for a three-phase, four-wire wye
system with a neutral ground Use a delta (three-phase,
resistance (NGR), a three-phase, three-wire) configured SPD if
three-wire delta SPD will want the presence of a neutral wire
to be specified and used. is not known
In a wye system, the neutral
and ground are both located
at the center, as shown in
Figure 6. If the neutral is
bonded to the ground, the
system will remain unchanged
Neutral
under fault conditions. Ground
In the case where the neutral is C
not bonded to ground and a fault
FIGURE 6. WYE SYSTEM
condition is present, the ground
will move towards the phase
that has the fault.
Figure 7 shows a fault condi- A
tion on phase C. The result is
phase A to ground and phase B B
to ground are now at line to line
voltage instead of line to neutral
voltage. If a three-phase, four-
wire wye SPD was installed in
an application where the neutral
was not bonded to ground and a
fault condition occurred on one
of the phases, the result would
be SPD failure.
Neutral
Ground
FIGURE 7. PHASE C FAULT CONDITION

Surge current per phase How to calculate surge Facility-wide surge As demonstrated, the two-stage
(industry definition) current per phase suppression approach ensures that both
types of disturbances are sup-
Engineers/specifiers routinely The per-phase rating is the total As recommended by IEEE
pressed to negligible levels at
install TVSS devices at the ser- surge current capacity (Emerald Book 1992), TVSS
the branch panel (<150V
vice entrance and key branch connected to a given phase units need to be coordinated in
let-through). This prevents
panels to protect sensitive conductor. For example in a wye a staged or cascaded approach.
high-energy transients from
microprocessor loads such as system, L1-N and L1-G modes IEEE provides the following
damaging components and
computers or industrial control are added together because recommendations:
ensures that fast low-level
devices from damaging surges surge current can flow on either ...For large surge currents, ringwaves will not degrade or
and noise. These devices are parallel path. If the device has (transient) diversion is best disrupt the operation of down-
available in a wide range of only one mode (e.g., L1-G), then accomplished in two stages: stream microprocessors.
sizes to meet different applica- the per-phase rating is equal to the first diversion should be per-
tion requirements. Suppressors the per-mode rating because This ensures the system per-
formed at the service entrance
located at the facilitys service there is no protection on the formance meets the following
to the building. Then, any
entrance must handle higher L1-N mode. IEEE (Emerald Book, 1992)
residual voltage resulting from
energy surges than those locat- recommended performance:
Note: N-G mode is not included the action (of the suppression
ed at branch panels. in the surge current per-phase device) can be dealt with by a While electromechanical
TVSS devices are classified by calculation. second protective device at the devices can generally
the units maximum surge cur- power panel of the computer tolerate voltages of several
Almost all suppressor manufac-
rent measured on a per phase room (or other critical load). In times their rating for short dura-
turers follow this convention.
basis. Surge current per phase this manner, the wiring inside tions, few solid-state devices
However, there are some com-
(expressed as kA/phase) is the the building is not required to can tolerate much more than
panies who attempt to cause
maximum amount of surge carry the large surge current to twice their normal rating.
confusion by inflating their surge
current that can be shunted and from the diverter at the end Furthermore, data processing
current ratings using a non-
(through each phase of the of a branch circuit. equipment can be affected by
standard method for calculating
device) without failure and is fast changes in voltages with
surge current per phase. As ...proper attention must be
based on the IEEE standard relatively small amplitude
shown below, the correct mode given to coordination of cascad-
8 x 20 microsecond compared to the hardware-
and phase ratings are displayed. ed surge protection devices.
test waveform. damaging overvoltages.
Figure 8 demonstrates the
As per NEMA LS-1, TVSS manu- Summary effectiveness of a suppression
facturers are required to publish system when used in a two-
the level of surge protection Surge current per phase (kA/
phase) has become the standard stage (cascaded) approach.
on each mode. A delta system
can employ suppression com- parameter for comparing
ponents in two modes (L-L or suppression devices. Most
L-G). For wye systems, shunt reputable manufacturers pub-
components are connected L-G, lish surge current ratings on a
SPD
L-N and/or N-Gs. per-mode and per-phase basis.
Some suppression manufactur- SPD
ers may hide surge current 480V 120V/
ratings or make up their own 208V
method to calculate surge Computer
ratings. Avoid manufacturers sensitive
who do not clearly publish these Stage 1 protection
loads
industry standardsper-phase (service entrance)
and per-mode surge capabilities. Stage 2 protection
(branch location)
System test parameters:

TABLE 3. EXAMPLE OF WYE SYSTEM IEEE C62.41 and C62.45 test procedures using C3 impulse
MODES OF PROTECTION PER PHASE (KA/) 480V main entrance panels; 100 feet of entrance wire;
480/208V distribution transformer; and 120/208V branch
MODEL L-N L-G NG (L-N + L-G)
120 kA per phase TVSS 60 60 60 120
Inputhigh energy
transient disturbance:
20,000V IEEE category C3 impulse 20,000V
Best achievable
performance with single TVSS
at main panel (800V at Stage 1)
Two stage (cascade approach)

achieves best possible protection
(less than 100V at Stage 2)
25 uS 50
FIGURE 8. FACILITY-WIDE PROTECTION SOLUTIONSIEEE EMERALD BOOK

RECOMMENDS A CASCADE (OR 2-STAGE) APPROACH

Debunking the surge 50% of recorded direct When lightning hits the earth, Why is 250 kA/phase an
current myth, Why lightning strokes are less a powerline or facility, most of acceptable rating?
excessive surge current than 18,000A the energy flashes to ground or
The above discussion proves
ratings are not required 0.02% of the strokes could is shunted through utility surge
that 500 kA lightning stroke
have a surge current arrestors. The remaining energy
current can not exist on the AC
When will it stop? of 220 kA that is induced on the AC power
powerline. If IEEE recommends
system is called surge current
It seems that every year surge An unusual event was testing service entrance TVSS
(measured in kA). The surge cur-
suppressor manufacturers are recorded that had a stroke units to 10 kA, why do many
rent shunted by a suppressor is
increasing the surge current of approximately 450 kA; suppliers, including us, suggest
a small fraction of the lightning
ratings of their devices. For however, this is a a 250 kA/phase device
stroke current.
example, a well-known TVSS controversial measurement be installed? The answer is
manufacturer has made the Based on available research, reliability, or, more appropriately,
following recommendations to IEEE recommends using the life expectancy.
TVSS myth 20 kV, 10 kA combination wave
the consulting community for A service entrance suppressor
main panel surge protection: A TVSS manufacturer may as the representative test for
will experience thousands of
suggest a one in a million induced lightning surges at ser-
TABLE 4. MANUFACTURER surges of various magnitudes.
lightning stroke will be con- vice entrance locations. Above
RECOMMENDATIONS Based on statistical data, we can
ducted on the AC distribution this amount, the voltage will
determine the life expectancy
RECOMMENDED SURGE system and enter a facilitys exceed BIL ratings causing
CURRENT RATING of a suppressor. A properly
YEAR (KA/PHASE) service entrance. To bullet-proof arcing in the conductors or
constructed suppressor having
a facility against this stroke distribution system.
1993 250 kA/phase a 250 kA/phase surge current
current, a surge suppressor In summary, low voltage wir- rating will have a life expectancy
1994 350 kA/phase with a surge current rating of ing (<600V) is not capable of greater than 25 years in high-
400 kA/phase is required. conducting the lightning stroke exposure locations.
1995 >500 kA/phase
currents as presented in
2006 >1000 kA/phase Reality Note: A 400 kA/phase device
Figure 9. Engineers should not
would have more than 100
The same model has changed Stroke current has no relation- use lightning stroke current as
yearswell beyond reasonable
surge ratings three times in last ship to the surge current a means of specifying suppres-
design parameters.
several years! In fact in 1998, conducted on the AC power sors having a rating over
the company also introduced a distribution system. There is no 400 kA/phase. Should a suppressor fail, it is
unit that is theoretically rated to technical reason to specify a most likely due to temporary
650,000A per phase. The above surge suppressor having 400 kA/ overvoltage (TOV) on the utility
example illustrates how some phase surge current rating. powerline; for instance, when a
manufacturers use irrelevant 120V circuit rises to 200 Vac or
justifications to promote the sale greater. A larger-sized suppres-
Discussion sor will not protect against TOV.
of a premium-priced suppressor.
In Florida (worst case in the
We believe it is time to debunk
U.S.), there are six ground
the game and present the facts Stroke current (kA)
flashes/year/km2 (IEEE C62.41).
on what is an acceptable level
A facility occupying one acre 250
of surge current for service (0.02;220)
will experience one direct strike
entrance locations.
every 40 years. Based on the 200
percentages in Figure 9, the
Why stroke current is facility will experience one
not related to TVSS stroke exceeding 200 kA 150
surge current every 800 years.
The stroke current associated The crest current magnitude of 100
with lightning is not related to a an actual lightning strike varies
suppressors surge current rat- widely. Typical surges conducted
ing. It is physically impossible to 50
or induced into wire line facilities 18
have the energy associated with would be considerably smaller
a lightning stroke travel down because of the availability of 0
the AC power conductors. alternate paths. As a result, 0.01 0.1 1 10 50 100
Figure 9 is a graph published by protectors at the termination of Percent of strokes in which current exceeds ordinate (%)
the IEEE Std. 1100 (the Emerald these facilities are normally not
Book) and by the ANSI/IEEE designed to withstand the full FIGURE 9. DISTRIBUTION OF LIGHTNING STROKE CURRENTS
C62.42 committee responsible crest current of direct strokes.
IEE STD. C62.42, 1992 PAR 3.1.1.
for surge protection devices.
The IEEE lightning research pro-
vides the following conclusions:
Stroke current is related to
the lightning strike (traveling
between a cloud and earth
or between clouds)

Surge arrestor vs. surge The evolution of surge This is satisfactory for insulation When selecting a suppressor,
suppressor protection devices protection on transformers, look for a quality device having
(also called TVSS) panelboards and wiring. For the following features:
The use of surge protection
variable frequency drives (VFDs), Low let-through under IEEE
devices (surge suppressors) is In todays computer age, the
computers, PLCs and other Category B3, C1 and C3
growing at over 20% per year. use of solid-state (nonlinear)
sensitive equipment, test waves
Suppressors are now routinely loads is increasing dramatically.
however, the solid-state com-
installed at the service entrance Research by utilities and other Independently tested to the
ponents will be damaged or
and key down-stream panel- groups estimated that 70% of published surge current
upset by these surges.
board or motor control center utility loads are consumed by ratings (per phase)
Using suppressors at the service
(MCC) locations to provide electronic equipment such as
entrance and key branch panels, Includes internal fuses
clean power to solid-state loads. drives, PLCs, computers,
the surge will be effectively
Currently, there is some confu- electronic ballasts, telecommuni- Includes internal monitoring
reduced to under 100V.
sion between the application of cation equipment, and so forth. features (for both open and
surge arrestors and surge sup- Note: If a TVSS and lightning shorted MOV failures)
Modern-day electronic equip-
pressorsespecially in industrial arrestor are both used at a ser-
ment is getting faster, smaller, Includes electrical noise
facilities, water treatment plants vice entrance switchboard, the
more efficient and very complex. filtering (55 dB at 100 kHz)
and other areas where arrestors TVSS will do all of the work. It
These improvements have been
were predominately used. This will turn on earlier and shunt Small footprint design for
made in all microprocessor-
section explains the differences most of the surge current. more effective installation
based equipment over the years,
in performance and application and this progress will continue. Many water-treatment plants, Listed under UL 1449, UL
between the two technologies. telecommunication facilities, 1283, and CSA approved
The tradeoff in faster speed and
hospitals, schools and heavy
The evolution of surge/ lower cost is that the micro-
industrial plants utilize TVSSs
lightning arrestors processor loads are becoming
instead of surge arrestors to
increasingly more susceptible
In the past, when nonlinear or provide protection against
to the effects of transients
solid-state devices such as the effects of lightning, utility
and surges.
computers, programmable logic switching, switching electric
controllers (PLCs) and drives As a design objective, the IEEE motors, and so on. New sup-
were not yet in use, relays, Emerald Book (and the CBEMA pressor designs can now be
coils, step switches, motors, curve) recommend reducing integrated into motor control
resistors and other linear loads 20,000V-induced lightning surge buckets, switchboards and other
were the standard. Utility com- disturbances down to two times distribution equipment, providing
panies and end users were nominal voltage (< 330V peak). more effective performance and
concerned with how to protect To achieve this level of perfor- eliminating installation problems.
electrical distribution systems mance, surge suppressors were
from lightning surges. Their developed. Since the mid-1980s,
objective was to ensure that these devices have become the
voltage surges did not exceed preferred choice for protecting
the basic insulation level (BIL) loads within any facility.
of the conductor wires, trans- Lightning arrestors were
formers and other equipment. designed to protect the electrical
Consequently, arrestors were distribution system and not the
developed for use in low, medi- sensitive solid-state equipment
um and high voltage applications from the effects of lightning.
at various points in the transmis- As in Table 5, lightning arrestors
sion and distribution system. have a high let-through voltage,
The fact that these devices cre- the key performance factor
ated a crowbar between the for protecting electronic loads.
phase conductor and ground did Under the IEEE Category C3
not matter to these loads if it test wave (20 kV, 10 kA), the
cleared within a few cycles. let-through voltage is typically
Arrestors are still used in the over 1200V (on a 120 Vac
electrical industry primarily system).
along the transmission lines and
upstream of a facilitys service
entrance. Arrestors are available
in various classes depending
upon their withstand capabil-
ity (e.g., station vs. distribution
class). At the service entrance
location on low voltage systems
(600V and below), surge sup-
pressors are now replacing the
use of arrestors.

TABLE 5. DIFFERENCE BETWEEN ARRESTORS AND SUPPRESSORS
SURGE ARRESTOR SURGE SUPPRESSOR
DESCRIPTION 480V (277V L-N) 208V (120V L-N) 480V (277V L-N) 208V (120V L-N)
Let-through voltages
(based IEEE test waves):
Cat. C3 (20 kV, 10 kA) >1500V >1000V 900V 470V
Cat. C1 (6 kV, 3 kA) >1200V >1000V 800V 400V
Cat. B3 (6 kV, 500A, 100 kHz) >1500V >1000V 200V <150V
Internal monitoring capabilities No No Yes (most quality devices) Yes (most quality devices)
(identify internal failure and
activate remote alarm or lights)
EMI/ RFI filtering No No Yes (most quality devices) Yes (most quality devices)
Internal fusing No No Yes (most quality devices) Yes (most quality devices)
(overcurrent protection)
Design Gapped MOV Gapped MOV MOV/filter (hybrid) MOV/filter (hybrid)
Interrupts power (crowbar) Yes (typical 1/2 cycle) Yes (typical 1/2 cycle) No No
Failure Explosive Explosive Trips breaker/fuse Trips breaker/fuse
Warranty Limited Limited 5 years or more 5 years or more
(on most quality devices) (on most quality devices)
Life expectancy Limited Limited >25 years >25 years
(throw-away devices) (throw-away devices) (if sized appropriately) (if sized appropriately)

Benefits of hybrid filtering in transients and EMI/RFI noise Basic suppressor (MOV Only)
surge protection devices disturbances. In comparison,
basic suppressors do not have
L
A surge suppressor (TVSS
filter components and can only
device) prevents harmful surge
suppress high voltage distur-
voltages from damaging or
bances. Table 6 summarizes the Surge
disrupting sensitive electronic
key differences between the current
MOVs Load
equipment. There are two types
two technologies.
of suppression devices:
a) Ringing transient
Basic suppressor devices
suppression
Transient suppressors that N
use only voltage-dependent Studies performed by ANSI/IEEE
components such as metal and other organizations indicate Hybrid filter
oxide varistors (MOVs) or the oscillatory ringwave is the
most common type of transient
L
silicon avalanche diodes (SADs).
waveform occurring within a
Hybrid filter devicesHybrid
facilitys electrical distribution
devices that employ a parallel
system. Normal impedance Surge Filter
capacitive filter circuit in addi-
characteristics of a low voltage current Load
tion to MOVs. Since these
distribution system create
products are able to eliminate
ringing oscillatory waves at
low-amplitude transients and
frequencies between 50 kHz
high-frequency EMI/RFI noise,
and 250 kHz. N
they are widely specified for
commercial, hospital and indus- Internal transients at these
trial facility construction projects. frequencies are common and FIGURE 10. BASIC SUPPRESSOR AND HYBRID FILTER
(See Figure 10.) can result in damaged inte-
grated circuits, system lock-ups,
Unfortunately, it is often difficult
reboots or other operational 6000
to distinguish between hybrid Ringwave (Cat. B3,
problems. To model this ringing
filter and basic suppressors 6000V 100 kHz)
effect, ANSI/IEEE C62.41
when reviewing the perfor-
(2002) recommends testing
mance specifications provided
all suppression devices to the
by the manufacturer of either 4000
100 kHz Ringwave (Category
type of device. In addition,
B3; 6000V, 500A waveform).
specifying consultants are often
(See Figure 11.)
unsure of the practical benefits
offered by the filter compo- Published let-through voltages
are then used to compare 2000
nents. This section describes
the differences between the suppression performance.
two technologies when
installed in an electrical
distribution system. 0
A hybrid filter protects sensitive
electronic equipment against
high-amplitude lightning
impulses, low-level ringing 2000
4000
0 10 20
FIGURE 11. RINGWAVE
TABLE 6. COMPARISON OF SUPPRESSOR TECHNOLOGIES
TVSS performance criteria Hybrid filter Basic suppressor
Repetitive surge withstand capability Longer life expectancy Limited life

Ringing transient suppression <300V let-through >900V let-through
Electrical noise attenuation 50 dB @ 100 kHz Poor attenuation
Facility-wide noise filtering Coordinated from service entrance to branch panels Not achievable

Figure 12 illustrates the superior b) EMI/RFI noise attenuation For premium performance, the Summary
performance of a hybrid filter filter attenuation should exceed
Filters remove high-frequency TVSS filters offer significant
suppressors when tested to the 50 dB at 100 kHz (based on
EMI/RFI noise associated with benefits that enhance the power
standard IEEE B3 Ringwave. MIL-STD-220).
loads such as: quality within a facility. This
Filter components provide a Note: Have the suppressor sup-
Variable speed drives section illustrates why TVSS
low-impedance path at higher
plier provide actual test results filters are now the most com-
frequencies (e.g., 100 kHz) Photocopiers to ensure this level of filtering is monly specified suppression
allowing impulses to be shunted being provided.
Large UPSs technology.
away from sensitive loads, at
any phase angle along the 60 Hz Arc welders Manufacturers may offer
AC sine wave. This sine wave c) System noise/ misleading claims and avoid
tracking feature suppresses
SCR controlled loads suppression capability publishing accurate performance
disturbances at much lower Light dimmers TVSS filters installed at standards. Engineers should
levels than possible with a basic the service entrance and ensure the suppression
These types of noise generat-
suppressor (nonfiltered device). branch panels meet with the device chosen offers sufficient
ing loads are found in almost
IEEE-recommended approach ringwave suppression, noise
Without a filter, the MOVs are every facility. IEEE defines noise
to facility protection. Please attenuation and provides coor-
able to clamp the transient only as disturbances less than two
see Facility-wide surge dinated facility protection. TVSS
once when the voltage exceeds times peak voltage (e.g., less
suppression on page 9 for manufacturers claiming to offer
the turn on point of the MOV. than 340V peak on 120V
additional information. sine wave tracking or filter com-
As shown in Figure 12, the systems).
ponents must support these
MOV let-through voltage is In addition, a system-wide
The key performance filter claims by submitting test results
significantly higher due to the suppression design provides
testing standard is the MIL- and spectrum analysis. Without
impedance associated with enhanced normal mode and
STD-220A, 50 Ohm insertion these submittals, it is likely a
wire lead lengths and the MOV common mode noise attenua-
loss test. Manufacturers should low-end suppressor will be
operating characteristics. This is tionsignificantly greater than
publish noise attenuation lev- supplied rather than the
over three times the let-through a stand-alone device.
els measured in decibels (dB) required hybrid filter.
voltage of the TVSS filter. As a
obtained at 100 kHz. Test data
result, the level of protection
based on computer simulations
provided is limited.
such as SPICE programs are not
reflective of actual environmen-
tal conditions, and are therefore
not acceptable for comparing
filter performance. Also note
that published dB ratings at
frequencies over 1 MHz are
meaningless for panel hybrid
filter products. Above 1 MHz,
EMI/RFI noise does not travel on
the conductor (i.e., it is radiated
and travels in the atmosphere).
Input wave: IEEE B3 ringwave

(6000V, 500A, 100 kHz)
600
No filter
400
Poor filter
200
Quality filter
Voltage (volts)
(55 dB at 100 kHz)

0
200
400
600
0 50 100 150
Time (microseconds)
FIGURE 12. RINGWAVE SUPPRESSION CAPABILITIES

Factory automation (PLCs) 1. Allen-Bradley SLC500 2. Siemens AG automation 3. Allen-Bradley publication
and their need for surge operational manual group EWA 4NEB 811 6130-02 1785-6.6.1
suppression 17471002, Series A
Measures to suppress interfer- Electromagnetic interference
End users often ask us why our Most industrial environments ence are frequently only taken (EMI) can be generated when-
surge protection is necessary are susceptible to power when the controller is already ever inductive loads such as
for protecting process control transients or spikes. To help in operation and reception relays, solenoids, motor starters
systems. Most people assume ensure fault-free operation and of a signal has already been or motors are operated by hard
that programmable controls and protection of equipment, we affected. The overhead for such contacts such as pushbuttons
automation equipment are fully recommend surge suppression measures (e.g., special contac- or selector switches. Following
protected from power distur- devices on power to the tors) can often be considerably the proper wiring and grounding
bances. As the following section equipment in addition to reduced by observing the follow- practices guards the processor
explains, PLC manufacturers and isolation equipment. ing points when you install your system against the effects of
service technicians recommend Lack of surge suppression on controller. These points include: EMI. However, in some cases
the use of surge suppressors inductive loads may contribute Physical arrangements of you can use suppression net-
and filters to prevent downtime to processor faults and sporadic devices and cables works to suppress EMI at
and equipment damage due to operation. RAM can be corrupt- its source.
surges and electrical line noise. Grounding of all inactive
ed (lost) and I/O modules may metal parts Regardless of the manufacturer,
A major study on how power appear to be faulty or electronic equipment is suscep-
disturbances affect process reset themselves. Filtering of power and tible to power disturbances.
control systems has been con- signal cables This results from two
ducted by Dranetz Technologies Shielding of devices contributing factors:
and PowerCet corporation. and cables 1. Processors themselves are
Results of the study indicate increasingly complex with higher
that impulses, surges and Special measures for
interference suppression chip density and lower
electrical noise cause the operating voltages.
following equipment problems:
2. The growing use of distur-
Scrambled memory bance generating loads such
Process interruption as adjustable frequency drives,
Circuit board failure capacitor banks, inductive
loads and a wide variety of
AC detection circuits cause robotic equipment.
false shutdown
Eatons series type TVSS filters
Setting calibration drift were developed exclusively for
Power supply failure the protection of automation
equipment used in industrial
Lock up environments. With up to 85
SCR failures dB of noise attenuation and
outstanding transient suppres-
Program loss
sion, these products are well
Digital/analog control suited for the protection of
malfunction sophisticated microprocessor
Sensitivity to electrical loads. A series power line filter
interference varies dramatically is extremely cost-effective and
from one system to another, less than one third the cost of a
depending upon grounding con- typical service call.
ditions, equipment sensitivity, Consider improving your
system design and quantity of control system and your bottom
electronic equipment in line reliability.
the area.
Facility downtime and repair
costs associated with these
power quality problems repre-
sent a growing concern for
engineers and maintenance
staff. Power protection is now
widely recognized as an impor-
tant factor in the design of
process control systems. Major
PLC manufacturers such as
Allen-Bradley and Siemens
provide the following recom-
mendations:
Dranetz Field Handbook For Power
Quality Analysis, 1991

Surge protection devices with not equally shared across the 2. Equal current sharing to Since all MOVs attached to the
replaceable modules MOVs. Most manufactures each MOV plane are at the same potential
match the performance of and all the MOVs are electri-
A surge protective device (SPD) The SPDs internal wiring must
the MOVs to achieve the cally matched, surge current is
design that is offered by sev- ensure that each component is
specified performance. A new equally shared. Stress on the
eral manufactures is known electrically balanced. In other
module will not be matched MOVs is reduced because each
as a modular design. Modular words, a suppressor manufac-
to the modules already in MOV carries a smaller and equal
designs include parts that can turer must ensure the following
the product proportion of the total surge,
be replaced in the field. The performance criteria are met:
Many manufacturers of mod- resulting in significantly longer
most common replaceable mod-
Integrity of rated
ular designs utilize banana
life expectancy compared to
ule version is a metal box with surge performance
pin connectors instead of low- devices that do not provide
replaceable surge components
impedance bolt-on connection All surge paths must achieve equal current sharing.
housed in a smaller plug in
plastic box. or leads. During high surge the rated surge current Features of the
currents, the mechanical Life expectancy SurgePlane include:
In an SPD, the most commonly
forces can rip these con- Lowest possible self-induc-
used surge suppression com- The total device must meet its

nectors out of their sockets. tance due to the high
ponent is an MOV (metal oxide lifetime performance rating.
Many environmental condi- surface area
varistor). The MOV becomes a
tions can degrade these A possible result to SPDs that
conductive component when Mutual inductance is reduced
connectors, as they rely do not share surge current
the voltage across it exceeds due to the geometry of
solely on spring force to equally is premature failure.
a certain level known as the the circuitry
keep the connection Premature failure is a common
maximum continuous operating
voltage (MCOV). Once the volt- Performance specifications problem in modular designs Reduced let-through voltage
age exceeds MCOV, the current can be misleading. Often since newer and older Improved reliability
is allowed to flow through the the published suppression modules do not have the same
MOV, which then passes the ratings are for the individual MOV voltage, and therefore Since there are significant
surge to ground. For SPDs that module and not for the entire experience a reduction in surge quality differences among surge
are modular, the MOVs are built SPD unit. Some manufactur- current capacity. protection devices (SPDs), we
into these plastic boxes that are ers have designed modular encourage engineers to check
The Clipper Power System,
available for field replacement if products just for this reason. the SPDs electrical founda-
Visor series (CPS) and Eaton
the internal MOV was damaged. It is important to get the SVR tion. The consulting engineer
TVSS units are designed to uti-
(ULs surge voltage ratings, should verify that surge cur-
Some SPD manufacturers lize the benefits of ground plane
markings required on all rent is equally shared among
promote modular design to technology in the construction
UL- listed products) ratings components and other possible
minimize their production costs. of suppressors. The electrical
and surge current ratings for problems are dealt with before
Plus, the use of modules create foundation of all our Visor SPDs
both the module and for the accepting them as equal.
an aftermarket business for the employ a multilayer, low-imped-
complete product ance SurgePlane circuitry.
SPD manufacturer. However,
there are a number of potential Another aspect to look at closely Because power surges and
technical flaws with modular is theoretical surge current electrical line noise are high-
designs. ratings. In order for accurate frequency disturbances, the
theoretical surge current ratings, current travels on the surface
If one module is damaged,
there are two design criteria that of the plane due to skin effect.
the remaining undamaged
must be considered. The surge plane design provides
modules begin to compen-
sate for the lost module, the largest possible conduct-
resulting in stress to the 1. Integrity of internal wiring ing area without the drawbacks
undamaged modules. This of heavy gauge wire. At these
Low-end surge suppression
may lead to a second failure frequencies, the impedance (self
devices may use small diameter
before the first module and mutual inductance) of the
circuit traces or wires, which
is replaced solid copper plane is significantly
cannot handle the rated surge
lower than even large diameter
Many failures result in current. Exposure to a large
wire or bus bars.
unacceptable damage to the transient the modules can
interior of the metal box. survive, but the total product
Replacement of the modules cannot survive, leaving down-
is not sufficient to get the unit stream loads unprotected.
back to operating condition. Most of the time these potential
These failures require replace- wiring deficiencies are inside of
ment of the complete unit the SPD and hidden from the
A damaged module may also customer or specifying engineer.
cause unbalanced protection,
in which the surge current is

Why silicon avalanche diodes the device is affected more by 700
are not recommended for AC the internal wiring/connection Small MOV (20 mm)
powerline suppressors than the speed of the SAD (or 600 Large SAD (5 kW) MOV
MOV). For example, a SAD may SAD
A surge protection device, also Failure
react in one picosecond, but the Failure
called a TVSS device, is used 500
internal wiring and connecting
to protect semiconductor loads
leads within the SPD add induc-
Voltage (V)
from powerline transients. SPDs 400
tance (about 1 to 10 nanohenrys
are installed in the AC power
per inch). This inductive effect is
system at the service entrance 300
the dominating factor in overall
and panelboards, and some-
response timenot the SAD
times at the load. SPDs are also 200 Silicon avalanche diode: Note 52 SADs are
reaction time.
required on data communication equivalent surge current rating as the 1 small MOV
lines to prevent ground loops 3. Note that hybrid filters (MOVs 100 illustrated. For a complete device, a significant
and induced surges, which can combined with capacitive filter- number of SADs are required.
damage equipment. ing) react the fastest because
0
the capacitors activate 1 10 100 1000 10000
In AC power applications, over
instantaneously to any high
95% of SPDs use metal oxide Surge current (A)
frequency surge.
varistors because of their high-
FIGURE 13. SILICON AVALANCHE DIODES HAVE LIMITED ENERGY CAPABILITY
energy capability and reliable Myth number two: MOVs
clamping performance. For degrade resulting in short life
added performance, hybrid expectancy of the SPD and MOVs are rated from 6500A to Failure mode. SAD manufactur-
designs (MOVs and capacitive unsafe failures. SADs do not 40,000A, making them more ers claim that their units do not
filter) are typically specified. degrade and are safer to use. reliable for AC power systems. degrade. Rather than degrade,
A small number of SPD manu- Life expectancy of SADs is Quality SPDs often parallel the SAD fails in a short circuit
facturers still promote the use of much lower than that of an MOVs to achieve surge current mode at much lower energy
silicon avalanche diodes for AC MOV (see Figure 13). A single ratings in excess of 250,000A levels than a MOV. A properly
applications. These companies SAD will be damaged by a surge per phase. These results can be constructed MOV suppressor
attempt to scare customers under 1000A. Given that IEEE verified through independent will not degrade, even when
into buying a premium-priced C62.41 requires SPDs to with- testing at lightning labs. At exposed to thousands of
unit by publishing misleading stand 10,000A surges, SADs these ratings, the SPD will high-energy strikes. Ask your
information about MOV surge do not have sufficient energy operate effectively for over 25 supplier to provide indepen-
components. The following sec- capabilities for service entrance years in IEEE-classified high dent testing to guarantee the
tion summarizes the marketing or branch panel applications. To exposure environments. device achieves the published
claims and technical insights hide this weakness, SAD devic- surge current ratings (and thus,
es often publish Joule ratings Paralleling SADs is more difficult the required life expectancy).
regarding SADs suppressors.
or wattage instead of publishing than with MOVs. Suppressors Degradation problems do exist
surge current capacity per phase using parallel SADs require a sig- with the very inexpensive surge
Three SAD myths and reality nificant amount of components,
(a more reflective performance bars. These devices are usu-
Myth number one: SADs have criteria). which reduce the overall ally manufactured offshore and
a faster response time (e.g., 5 device reliability. are poorly constructed utilizing
picosecond compared to 1 nano- Note: IEEE and NEMA do not underrated MOVs. These low-
recommend the use of Joule Given the limited energy ratings
second for MOVs). The faster of SADs, these devices are not quality devices should not be
SAD response time results in ratings for SPD comparison. compared to the SPDs typically
recommended for panelboard
improved SPD performance. or switchboard applications. used at panelboards or service
1. NEMA LS-1 and IEEE commit- Similarly, hybrid designs using entrance locations.
tees do not mention the use of MOVs and SADs do not achieve
response time as an SPD speci- component synergies. In
fication. All SPDs have sufficient high-energy applications,
response time to turn on and for example, the SADs are
shunt surges. The response the weak link because the
time of an MOV is 1000 times SADs and MOVs cannot be
faster than the time it takes for coordinated to work together.
a surge to reach full current (i.e.,
8 microseconds). Response time
is not an appropriate criteria to
use when specifying SPDs.
2. The response time for a SAD
device is equivalent to that of an
MOV device. Response time of

Myth number three: SADs Summary Based on the proven track
provide tighter clamping record of performance, MOV-
There are a number of myths
than MOVs. based suppressors are highly
in the SPD industry. When
When exposed to IEEE-defined reliable. That is why almost
evaluating SPDs, it is important
test waveforms and UL 1449 all suppressors still employ
to evaluate the performance
test results, both MOV and SAD MOV components. For service
of the suppressor unit and not
devices have the same suppres- entrance or panelboard
compare individual internal ele-
sion voltage ratings. Accordingly, locations, SADs are not recom-
ments. In other words, SPD
UL does not regard SAD devices mended because of their limited
construction methods and inter-
as providing any better clamping energy capability. SADs are
nal wiring/fusing limitations are
than MOV based SPDs. primarily used to protect dataline
critical to overall performance.
and communication wires.
Independent testing is essential
when comparing the perfor-
mance of these units.
TABLE 7. COMPARISON OF COMPONENTS USED IN SURGE PROTECTION DEVICES
SPD component Advantages and Disadvantages
Metal oxide varistor (MOV) Highest energy capability, excellent reliability and consistent performance, better mechanical connectivity for
paralleling multiple components. Nonlinear clamping curve gradually degrades over repeated use (only at high
surge levels), moderate capacitance.
Silicon avalanche diode (SAD) Flatter clamping curve, excellent reliability and consistent performance. Very low energy capability, expensive.
Selenium cells Moderate to high-energy capability. Very high leakage current, high clamping voltage, bulky, expensive,
obsolete components.
Gas tubes High-energy capability, very low capacitive (requirement for data line applications). Unpredictable and unstable
repetitive behavior, crowbar to ground (unsuitable for AC systems), expensive.
Hybrid SPD MOV/filter is most common hybrid; incorporates the advantages of other components while overcoming the
problems associated with each individual component (achieves long life expectancy, faster response, better
clamping performance). Inherent problems with hybrid SPDs using MOV and SAD, or devices using selenium
cells (inability to have the various components work together).

Surge protective device 2. Why is there a need for TABLE 8. SUMMARY OF MAJOR SURVEY RESULTS ON THE
frequently asked questions surge protective devices? EFFECTS OF SURGES ON DIFFERENT MICROPROCESSOR
EQUIPMENT
1. What are surges (also called In the coming years, electronic
transients, impulses, spikes)? devices will represent half of Repetitive
disturbance
the electrical demand in the Impulse 4X Impulse 2X (noise)
An electrical surge (transient
United States. Electronics,
voltage) is a random, high-
consist of microprocessors that
energy, short duration electrical
rely on digital signals: fast on/ Impact to
disturbance. As shown in electronic loads
off coded sequences. Distortion
Figure 14, it has a very fast
on the power or signal lines Circuit board failure Yes Yes
rise time (110 microseconds).
may disrupt the sensitive signal
Surges, by definition, are sub- Data Yes Yes Yes
sequence. As electronic compo-
cycle events and should not be transmission errors
nents become smaller and more
confused with longer duration
powerful, they become more Memory scramble Yes Yes Yes
events such as swells or
sensitive. The tremendous pro-
temporary overvoltages. Hard disk crash Yes
liferation in the use of sensitive
High-energy surges can disrupt, electronic equipmentsensi- SCR failure Yes
damage or destroy sensitive tive by virtue of circuit density
microprocessor-based equip- (microchips having literally thou- Process interrupt Yes Yes Yes
ment. Microprocessor failure sands of transistors on a single Power supply failure Yes
results from a breakdown in the chip)is now incorporated
insulation or dielectric capability into almost every new electri- Program lock-up Yes Yes Yes
of the electronics. cal device. Surge protection is
Source: Dranetz Handbook for Power Quality
Approximately 80% of recorded now the standard technology
surges are due to internal for increasing the reliability and
uptime of microprocessors. Other references for the recom-
switching transients caused by mendation of surge protective
turning on/off motors, transform- Microprocessors can be devices includes:
ers, photocopiers or other loads. upset, degraded or
The IEEE C62.41 surge standard damaged by surge events.
IEEE Emerald Book
has created the Category B3 Depending on the magnitude (Std. 1100)
ringwave and the B3/C1 combi- of the surge, the system con- FIPS 94
nation wave to represent higher figuration and the sensitivity of IEEE C62.41
energy internal surges. the load. Table 8 summarizes
the results of a major survey Manufacturers (Allan-
Externally generated surges
conducted by Dranetz on the Bradley, Motorola,
due to induced lightning, grid
effects of surges on different other suppliers)
switching or from adjacent build-
ings account for the remaining microprocessor equipment. NEMA LS-1
recorded surges. The Category NFPA 780
C3 combination wave (20 kV,
10 kA) represents high-energy As a design objective, the IEEE
surges due to lightning. Refer to Emerald Book (and the CBEMA
the CPS Technote #1 for more curve) recommends reducing
information on IEEE 20,000V induced lightning surge
surge standards. disturbances down to two times
nominal voltage (<330V peak).
To achieve this level of perfor-
mance, surge suppressors were
developed. Since the mid-1980s,
surge protective devices mount-
ed at switchboards, panelboards
and MCCs have become the
preferred choice for protecting
all loads within a facility.
FIGURE 14. AN EXTERNALLY CREATED ELECTRICAL SURGE CAUSED BY

INDUCED LIGHTNING

3. Where do I need an SPD? the nominal system voltage), the 6. What criteria are A. Surge current per phase
Why do I need to implement MOV will quickly become a low- important when specifying 250 kA/phase for service
a two-stage approach? impedance path to divert surges a suppressor? entrance, 120 kA/phase for
As recommended by IEEE away from loads. The MOV A specification should focus panelboards or other locations.
(Emerald Book 2005), SPDs reaction time is nanoseconds on the essential performance, B. Let-through voltagespecify
should be coordinated in a 1000 times faster than the installation and safety require- the performance voltage rating
staged or cascaded approach. incoming surge. ments. A number of surge based on the three standard
The starting point is at the ser- In AC power applications, over specifications contain misleading IEEE test waveforms (IEEE
vice entrance. (Service entrance 95% of SPDs use metal oxide criteria that do not follow NEMA C62.41 Category C3 and B3
protection is also required by varistors because of their high- LS-1 or other recommended combination waves; and BE
NFPA 780.) The first surge energy capability and reliable performance standards. ringwave). Specify the required
diversion occurs at the service clamping performance. For The following are considered ratings for applicable nominal
entrance, then any residual added performance and SPD life essential performance/safety/ voltages (i.e., 208 vs. 480). This
voltage can be dealt with by a expectancy, a filter element is installation criteria for data should be requested as part
second SPD at the power panel used in conjunction with a specification: of the project submittal process.
of the computer room, or other the MOVs.
critical load (see Figure 15). This Silicon avalanche diodes (SADs)
two-stage approach will reduce are frequently used in dataline
20,000V induced lightning SPD
or communication surge protec-
surges well under 330V peak tors. They are not recommended SPD
as recommended by IEEE for use in high-exposure AC 480V 120V/
and CBEMA. applications due to their limited 208V
4. Is there a difference energy capabilities. Computer
between a TVSS and an SPD? Selenium cells were once used Stage 1 protection sensitive
(service entrance) loads
No, Underwriters Laboratories in surge applications, but are
(UL) uses the term transient now an outdated technology. Stage 2 protection
voltage surge suppressor, while They were used in the 1920s, (branch location)
NEMA, IEC and IEEE use surge but were replaced in the 1960s System test parameters:
protective device (SPD). An by the more efficient SADs and IEEE C62.41 and C62.45 test procedures using C3 Impulse
480V main entrance panels; 100 feet of entrance wire;
SPD/TVSS is a device that atten- MOVs. One TVSS company 480/208V distribution transformer; and 120/208V branch
uates (reduces in magnitude) continues to use selenium-
transient voltages. enhanced surge protection as a
5. How does an SPD work? marketing ploy to create
confusion with engineers. Inputhigh energy transient disturbance:
The design goal is to divert as 20,000V IEEE Category C3 Impulse 20,000V
Selenium cells are metallic
much of the transient distur- rectifiers (diodes) having a
bance away from the load as maximum reverse voltage of
possible. This is accomplished 25 Vdc. Many selenium plates Best achievable
by shunting the energy to are stacked together to create performance with single TVSS
ground through a low- sufficient voltage breakdown for at main panel (800V at Stage 1)
impedance path (i.e., the use in AC power circuits. When
surge suppressor). mounted in parallel with MOV Two stage (cascade approach)
achieves best possible protection
Metal oxide varistors are the components, selenium offers no (less than 100V at Stage 2)
most reliable and proven tech- performance, cost or application
nology to reduce transient advantages. In fact, they are
voltages. Under normal expensive and add considerable
conditions, the MOV is a high- space (which makes installation
more difficult). There are no pat- 25 uS 50
impedance component. When
ents on selenium cells. Time (microseconds)
subjected to a voltage surge
(i.e., voltage is over 125% of FIGURE 15. FACILITY-WIDE PROTECTION SOLUTIONS IEEE EMERALD BOOK
RECOMMENDS A CASCADED (OR 2-STAGE) APPROACH

C. Effective filternoise attenu- The industry standard is to pub- Based on available research, the Beware: Some manufacturers
ation at 100 kHz based on the lish surge current per phase maximum amplitude of a light- recommend installing SPDs hav-
MIL-STD-220 insertion loss test. by summing modes L-N + L-G in ning-related surge on the facility ing surge current ratings over
The attenuation should exceed a wye system and L-L + L-G in service entrance is 20 kV, 10 kA 250 kA per phase. In fact, some
45 dB (L-N modes). Specify that delta systems. combination wave (refer to IEEE are promoting ratings up to 600
insertion loss bode plots are Surge current capacity is used C62.41). Above this amount, the or 700 kA per phase. This level
provided as submittals. to indicate the protection voltage will exceed BIL ratings of capacity is ridiculous and
D. Integrated installation capability of a particular SPD causing arcing in the conductors offers no benefits to custom-
factory installed as part of the design, and should be used on or distribution system. ers. A 400 kA per phase device
distribution equipment. Check to a per phase and per mode basis Eaton recommends 250 kA would have approximately 500-
ensure the installation minimizes when specifying an SPD for a per phase for service entrance year life expectancy for medium
lead length. given application. applications (large facilities in exposure locationwell beyond
high-exposure locations), and reasonable design parameters.
E. Internal fusingsafety and Beware: Manufacturers are (Eaton is forced to build higher
overcurrent protection. 200 kAIC not required to have their units not more than 120 kA per phase
at branch panel locations. rated units to meet competitor
internal fusing system. independently tested to their specifications, however, we
F. Reliability monitor and published surge current capacity If IEEE and other research speci- strongly recommend that con-
Diagnostic systemfoolproof rating. Most published ratings fies the maximum surge to be sultants question suppliers who
status indication for each phase. are theoretical, and calculated 10 kA, why do many suppliers, promote excessive ratings for
A popular option is to include by summing the individual MOV including Eaton, suggest up to commercial reasons.)
Form C contacts for capabilities. Manufacturer A a 250 kA per phase device be
may claim a rating of 100 kA, installed? The answer is reliabil- Todays SPDs will not fail due to
remote monitoring. lightning surges. Based on two
but due to the poor construc- ity, or, more appropriately, life
G. Independent testingto tion integrity, the unit is unable expectancy. By increasing the decades of experience, the fail-
ensure a reliable construction to share current equally to each kA rating of the suppressor, you ure rate of an SPD is extremely
and design, specify that all man- MOV. Without equal current are not increasing performance, low (<0.1%). Should a suppres-
ufacturers submit results from sharing, the published surge but instead the life expectancy sor fail, it is likely the result of
an independent test lab verifying current rating cannot be met. of the suppressor. excessive temporary overvoltage
the device can achieve the pub- Specifiers should request that (TOV) due to a fault on the util-
lished surge current ratings (on a A service entrance suppressor ity power line; for example, the
manufacturers submit indepen- will experience thousands of
per mode and per phase basis). dent test reports from lightning nominal 120 Vac line exceeds
surges of various magnitudes. 180V (for many cycles). TOV will
For more information on speci- labs confirming the published Based on statistical data, we can
surge ratings. damage surge protectors and
fication recommendations or a determine the life expectancy other electronic loads. Should
copy of sample specification, All clipper units have been of a suppressor. A properly con- this rare event occur, call your
contact Eaton. independently tested to meet structed suppressor having a utility to investigate the prob-
7. What is surge or exceed their published surge 250 kA per phase surge current lem. (For more information on
current capacity? current capacities. rating will have a life expectancy TOV problems in international
8. What surge current capacity greater than 25 years in high environments, refer to the IEEE
Defined by NEMA LS-1 as: The exposure locations.
is required? article written by Eaton for
maximum 8/20 U.S. surge cur-
the 1997 INTELEC
rent pulse the SPD device is Surge current capacity is depen- conference, Australia).
capable of surviving on a single dent on the application and the
impulse basis without suffering amount of required protection.
either performance or degrada- What is the geographic location
tion of more than 10 percent of the facility and the exposure
deviation of clamping voltage. to transients? How critical is the
Listed by mode, since number equipment to the organization
and type of components in any (impact of downtime,
SPD may vary by mode. repair costs)?

9. What is let-through
voltage (clamping 1. Surge waveforms (defined by IEEE C62.41 1991)
voltage)?
Let-through voltage is the Cat. C3 Impulse
Surge current (A)

(20 kV, 10 kA)
Surge current (V)

amount of voltage that is not
suppressed by the SPD and Cat. B3 Ringwave
passes through to the load. (6 kV, 500 A, 100 kHz)
Figure 16 is an example of
let-through voltage. Cat. C1 Impulse
(6 kV, 3 kA) -
Let-through voltage is a per- -
formance measurement of a -
surge suppressors ability to Time (us) Time (microseconds)
attenuate a defined surge.
IEEE C62.41 has specified
test waveforms for service
2. Let-through voltage test SPD Measured let-
entrance and branch loca-
through voltage
tions. A surge manufacturer Test surge
should be able to provide waveform
let-through voltage tests
under the key waveforms Surge
(i.e., Category C3 and C1 generator
combination waveforms;
FIGURE 16. EXAMPLE OF LET-THROUGH VOLTAGES AND DIFFERENT IEEE DEFINED SURGE WAVEFORMS
Category B3 Ringwave).
Beware: The UL 1449 (2nd
Edition, 1988) conducts a 10. Why is installation important? As one specifier said, No 1. The device rating (quality of
500A let-through voltage What effect does it have on an matter which TVSS device the suppressor).
test. This test does not SPDs performance? you buy, it is the installation 2. The quality of the installation.
provide any performance Installation lead length (wiring) reduc- requirements/inspection that
are the most important factor For example, consider an SPD
data and is not a key es the performance of any surge having a 400V rating (based on
specification criterion. suppressor. As a rule of thumb, of the surge specification.
IEEE Cat. C1 test waveform).
Clamping voltage is often assume that each inch of installa- Published let-through voltage
tion lead length will add between 15 ratings are for the device/mod- Connected to a panelboard
confused with let-through with just 14 inches of #14 wire,
voltage. Clamping voltage and 25V per inch of wiring. Because ule only. These ratings do not
surges occur at high frequencies include installation lead length approximately 300V are added
refers to the operating char- to the let-through voltage.
acteristic of a metal oxide (approximately 100 kHz), the lead (which is dependent on the
varistor component and is length from the bus bar to the electrician installing the unit). The true let-through at the bus
not useful for comparing the suppression elements creates The actual let-through voltage bar is thus 700V.
performance of an SPD. The impedance in the surge path. for the system is measured at
clamping voltage is the volt- the bus bar and is based on
age when 1 mA of current two factors:
passes through an MOV.
Clamping voltage does not
include the effects of inter-
nal wiring, fusing, mounting Installation lead length can increase let-through voltage
lugs, or installation lead by 15 to 25V per inch
length.
Let-through voltage is a more
applicable test for SPDs, and Additional let-through voltage (additional to UL 1449 rating)
refers to the amount of volt- 1,000
age that is not suppressed 900 14 AWG
by an SPD when tested to an 209V (23%)
800
IEEE defined surge 10 AWG
waveform and test setup. 700
. 67V (75%)
600 4 AWG
500
400
Installation criteria order
300 of importance:
200 1. Lead length 75% reduction
2. Twisting wires 23% reduction
100 3. Large wire minimal reduction
0
3 ft. lead length 1 ft. lead length
Loose wiring Twisted wires twisted wires
FIGURE 17. ADDITIONAL LET-THROUGH VOLTAGE USING IEEE C1 (6000V, 3000A) WAVEFORM (UL1449 TEST WAVE)

11. Why should suppressors 3. Reduce wall space.
be integrated into the electri- Integrating the suppressor Side mounted SPD SPD Integrated
used for retrofit into panelboards,
cal distribution equipment eliminates the wall space taken
applications switchboards, MCCs
(panelboards, switchboards)? up by the externally mounted
Most consulting specifiers are suppressor (between two and
now requiring the gear manufac- three feet!).
turer integrate the suppressor 4. One source for warranty
inside the switchboard, panel- claims. Should a problem N
board or MCC. Integrated occur, the customer eliminates CPS
suppression offers a number potential warranty conflicts SPD
of key benefits compared to between manufacturers.
externally mounted applications: 5. Reduced installation costs.
1. PerformanceIntegrating the There is no contractor fees for
SPD into the electrical distribu- mounting SPDs.
tion equipment eliminates the G
The Cutler-Hammer Clipper G
installation lead length, ensuring Power System is integrated N
significantly improved into all of our low voltage
performance (much lower distribution equipment.
let-through values).
Through our innovative direct 208Y/120 panelboard
2. ControlThere is no chance bus bar connection, we limit (integrated vs. side-mounted SPD)
that field installation is done the lead length between the
incorrectly. By having the sup- SPD and electrical equipment.
pressor factory installed and 1000 Side-mounted SPD device
For example, the Clipper Power (assuming 14" lead length to bus)
tested, the specifier does not System carries a UL 1449 let-
have to check the installation 800
through voltage rating of 400V.
and force the contractor to
reinstall the device (a costly Through our zero lead length 600
and time-consuming process). direct bus bar connection, we
This reduces future claims and obtain a let-through voltage of 400
problems for the engineer and 420V at the panelboard bus Clipper: Integrated SPD
bar. A significant performance (direct bus bar connection)
end customer. 200
advantage over traditional cable
connected designs.
0
Surge
event
200
2.00 0.00 2.00 4.00 6.00 8.00 10.00
Microseconds
Benefits of integrated (clipper):

- Less lead length = lower let-through voltage
- Eliminates installation costs
- Less wall space
- Factory installed and quality tested
- Higher performance
FIGURE 18. INTEGRATED SPD PERFORMANCE
Some SPD manufacturers have In most cases, the original

obtained a UL procedure for panelboard manufacturers
installing their SPD into another nameplate data is not removed
manufacturers panelboard. and replaced by that of the SPD
When this occurs, the original manufacturer. This can cause
panelboard manufacturers UL problems for the end customer
label (UL67) is void, as is the as different panelboards within
warranty provided by that manu- this facility carry the nameplates
facturer. The SPD manufacturer from the original panelboard
then modifies and integrates manufacturer, but two separate
the SPD into its panelboard, and companies cover the warranty.
must assume all warranty and
liability issues regarding the
panelboard and SPD.

12. What is the benefit of 13. Why Joules and 14. Is an SPD with replaceable
filtering (sine wave tracking)? response time are modules superior to
Filtering eliminates electrical line irrelevant specifications? non-replaceable designs?
noise and ringing transients by Joule ratings are not an No. Some manufacturers
adding capacitors to the approved specification for promote a modular design to
suppression device. surge protective devices. IEEE, minimize production costs, and
(See Figures 19 and 20.) IEC and NEMA do not recom- create an aftermarket busi-
mend using Joule ratings when ness in modules. There are a
specifying or comparing surge number of technical flaws with
....................................
....................................
....................................
....................................
....................................
....................................
....................................
....................................
....................................
..................................................... suppressors, because they can many modular designs.
provide misleading and 1. If one module is damaged,
..................................................... conflicting information. For all modules should be replaced
example, on a 120V system, a (undamaged modules are
..................................................... 150V or 175V MOV could be stressed and provide unbal-
used. Even though the 175V anced protection). Eaton, as well
..................................................... MOV has a higher Joule rating, as several other manufactur-
the 150V has a much lower ers, recommends a complete
..................................................... let-through voltage and offers replacement, or replacement of
better surge protection. all modules to ensure safety
..................................................... Joule ratings are a function of and reliability.
let-through voltage, surge 2. Easy to cheat on performance
..................................................... current and surge duration specifications (often suppression
(time). Each manufacturer may ratings are for an individual
..................................................... use a different standard surge module; unit ratings are
wave when publishing Joules. not published).
Given the confusion regarding
Joule ratings, the power quality 3. Modular designs utilize
FIGURE 19. INTERNALLY GENERATED RINGWAVE industry does not recommend banana pin connectors to con-
the use of Joule ratings in nect modules rather than a low
Note: Ringwaves typically resonate within a facility at frequencies impedance bolt-on connection.
performance specifications.
between 50 kHz and 250 kHz.
Response timeAll suppres-
sors have sufficient response
..................................................... time to react to surges. In fact,
....................................
....................................
....................................
....................................
....................................
....................................
the MOV will react 1000 times

..................................................... faster than the surge. NEMA
and IEEE do not recommend
..................................................... using response time as a
..................................................... performance criteria when
comparing SPDs.
.....................................................
..................................................... Let-through voltage without filter

..................................................... 400
.....................................................
200
..................................................... Let-through voltage
with filter
..................................................... 0
FIGURE 20. EMI/RFI ELECTRICAL LINE NOISE

200
Note: Noise is any unwanted electrical signal that produces undesir-
able effects. Noise is typically less than two times peak voltage.
400
Hybrid SPDA device that Key filtering specifications:

combines the benefits of both MIL-STD-220A attenuation at -5 0 5 10 15
MOVs and filtering. A properly 100 kHz measured in dB. A Time (microseconds)
designed hybrid SPD will vastly higher dB rating (i.e., >40 dB)
outperform any SPD using reflects better performance FIGURE 21. FILTER PERFORMANCE BASED ON CAT. B3, 100 KHZ, 6000V
only MOVs.
Let-through voltage: IEEE
Beware: Filtering is often C62.41 Category B3
referred to as sine wave track- Ringwave. On a 120V system
ing or active tracking. These L-N should be <200V
are marketing terms and have
no relevance to filter perfor- UL 1283 listing for
mance. Not all SPDs provide noise filtration
filtering, and many SPDs claim
to possess sine wave track-
ing, sine wave contour, or
EMI/RFI noise attenuation, but
may not employ a quality filter.

15. Is maintenance required 16. What is the difference 17. Does an SPD give me
for an SPD? between a surge protector 100% coverage for
and an arrestor? electrical loads?
Maintenance is not a require-
ment for a quality SPD. A Prior to the microprocessor rev- No! An SPD protects against
quality SPD should last over 25 olution, most electrical devices surgesone of the most
years without any preventive were linear loads, relays, coils, common types of electrical
maintenance program. Note the step switches, motors, resistors, disturbances. Some SPDs also
recommendations by Dr. Ronald and so forth. Utility companies contain filtering to remove high
B. Standler (a leading authority and end users were primarily frequency noise (50 kHz to 250
on SPDs) in his book Protection concerned with preventing volt- kHz). They do not provide filter-
of Electronic Circuits from age surges from exceeding the ing against harmonic loads (3rd
Overvoltages, page 229: basic insulation level (BIL) of the through 50th harmonic equals
conductor wires, transformer 180 to 3000 Hz).
The protection circuit should
windings, and other equipment. An SPD can not prevent
require minimal or no routine
Consequently, lightning arres- damage caused by a direct
maintenance. Consumable
tors were developed for use in lightning strike.
components, such as fuses,
low, medium, and high voltage
should have an indicator lamp to A direct lightning strike is a very
applications. The fact that these
signal the need for replacement. rare occurrence; in most cases
devices create a crowbar
Requiring routine maintenance lightning causes induced surges
between the phase conductor
increases the cost of the protec- on the power line that are
and ground does not matter to
tion circuits, although the money reduced by the SPD.
linear loads, as this is cleared
comes from a different budget.
within a few cycles. There is no device that can
The SPD should come with prevent damage from direct
Lightning arrestors are still used
a diagnostic system that will lightning strikes.
in the electrical industry primarily
provide continuous monitoring
along the transmission lines and An SPD can not stop or limit
of the fusing system and
upstream of a facilitys service problems due to temporary over-
protection circuits (including
entrance. Low voltage systems voltage. Temporary overvoltage
neutral to ground) and be
(600V and below), now have is a rare disturbance caused by a
capable of identifying any open
surge protectors at the service severe fault in the utility power
circuit failures. The monitoring
entrance and branch panels or due to problems with the
system should also include a
in place of lightning arrestors. ground (poor or nonexistent N-G
detection circuit to monitor for
Surge protectors offer the bond). Temporary overvoltage
overheating (in all modes) due
following advantages over occurs when the Vac exceeds
to thermal runaway.
arrestors: the nominal voltage (120V) for
Low let-through voltage a short duration (millisecond to
(better performance) a few minutes). If the voltage
exceeds 25% of the nominal
Longer life expectancy system voltage, the SPD and
Improved safety (less destruc- other loads may become
tive debris if damaged) damaged.
Full monitoring capability An SPD device does not provide
Internal fusing backup power during a power
outage. An uninterruptible
Filtering capabilities to power system (UPS) is required
remove low level surge/noise to provide battery backup power.

Abbreviations References
ANSI American National Institute of Electrical and
Standards Institute Electronics Engineers (IEEE)
CSA Canadian Standards Standard 100-1988 standard
Association Dictionary of electrical and
electronic terms
EMP Electromagnetic pulse
IEEE Collection of guides
EMI Electromagnetic C62 and standards for
interference surge protection
IEC International IEEE Guide for surge
Electrotechnical C62.41 voltages in low
Commission voltage AC
IEEE Institute of Electrical power circuits
and Electronics IEEE Guide on surge
Engineers C62.45 testing for
NEMA National Electrical equipment
Manufacturers connected to low
Association voltage AC
power circuits
RFI Radio frequency
interference IEEE Emerald Book
(Std. 1100)
UL Underwriter
Laboratories UL 96 Standard for
safety installation
LEMP Lightning EMP requirements
NEMP Nuclear EMP for lightning
protection systems
UL 452 Standard for
safety- antenna
discharge units
UL 497A Standard for
safety secondary
protectors for
communication
circuits
UL 498 Standard for safety-
receptacle and
receptacle plugs
(including direct
plug-in devices)
UL 544 Standard for safety-
medical and dental
equipment
UL 1283 Standard for safety
electromagnetic
interference filters
temporary power
taps (power strips)
transient voltage
surge suppressors
NEMA Low voltage surge
LS-1 protective device

Eaton Corporation is a diversified PowerChain Management
power management company solutions help enterprises
ranked among the largest achieve sustainable and
Fortune 500 companies. The competitive advantages through
electrical group is Eatons largest proactive management of the
division and is a global leader power system as a strategic,
in electrical control, power integrated asset throughout
distribution, power quality, its life cycle. With Eatons
automation, and monitoring distribution, generation and
products and services. power quality equipment;
Eatons global electrical brands, full-scale engineering services;
including Cutler-Hammer , and information management
MGE Office Protection systems, the power system
Systems , Powerware , is positioned to deliver
Holec , MEM , Santak and powerful results: greater
Moeller, provide customer-driven reliability, operating cost
PowerChain Management efficiencies, effective use of
solutions to serve the power capital, enhanced safety, and
system needs of the industrial, risk mitigation.
institutional, government,
utility, commercial, residential,
IT, mission critical and OEM
markets worldwide.
Eaton Corporation
Electrical Group
China Note: Features and specifications listed
No.3, Lane 280, Linhong Road, in this document are subject to change
Changning District, without notice and represent the maximum
Shanghai 200335 capabilities of the software and products
Tel: +86 (21) 52000391 (Jack Wang) with all options installed. Although every
+86 (21) 52000360 (Stella Li) attempt has been made to ensure the
Email: EESS-China@Eaton.com accuracy of information contained within,
Eaton makes no representation about the PowerChain Management is a registered
2013 Eaton Corporation completeness, correctness or accuracy and trademark of Eaton Corporation.
All Rights Reserved assumes no responsibility for any errors or
Printed in China omissions. Features and functionality may All other trademarks are property of their
November 2013 vary depending on selected options. respective owners.

Surge Suppression Applictation Notes 2013

Uploaded by

Copyright:

Available Formats

Surge Suppression Applictation Notes 2013

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Surge Suppression Applictation Notes 2013

Uploaded by

Copyright:

Available Formats

Eatons guide to

Summary of applicable UL and IEEE standards

2 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 3

UL 1449 (1987) 1. Safety test (constructed of approved components in a safe manner).

Underwriter laboratories electrical distribution system Notes

4 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 5

A primary protector is required The document only describes

FIGURE 1. COMBINATION WAVE

6 EATON CORPORATION Eatons guide to surge suppression

FIGURE 3. IEEE C62.41 LOCATION CATEGORIES

Isokeraunic maps provide a good Number of surges per year

EATON CORPORATION Eatons guide to surge suppression 7

8 EATON CORPORATION Eatons guide to surge suppression

the ground fault condition. Use a delta (three-phase,

FIGURE 7. PHASE C FAULT CONDITION

EATON CORPORATION Eatons guide to surge suppression 9

System test parameters:

120 kA per phase TVSS 60 60 60 120

Two stage (cascade approach)

FIGURE 8. FACILITY-WIDE PROTECTION SOLUTIONSIEEE EMERALD BOOK

10 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 11

12 EATON CORPORATION Eatons guide to surge suppression

SURGE ARRESTOR SURGE SUPPRESSOR

EATON CORPORATION Eatons guide to surge suppression 13

FIGURE 11. RINGWAVE

TABLE 6. COMPARISON OF SUPPRESSOR TECHNOLOGIES

TVSS performance criteria Hybrid filter Basic suppressor

Repetitive surge withstand capability Longer life expectancy Limited life

14 EATON CORPORATION Eatons guide to surge suppression

Input wave: IEEE B3 ringwave

(55 dB at 100 kHz)

FIGURE 12. RINGWAVE SUPPRESSION CAPABILITIES

EATON CORPORATION Eatons guide to surge suppression 15

16 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 17

18 EATON CORPORATION Eatons guide to surge suppression

TABLE 7. COMPARISON OF COMPONENTS USED IN SURGE PROTECTION DEVICES

SPD component Advantages and Disadvantages

EATON CORPORATION Eatons guide to surge suppression 19

FIGURE 14. AN EXTERNALLY CREATED ELECTRICAL SURGE CAUSED BY

20 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 21

22 EATON CORPORATION Eatons guide to surge suppression

Surge current (A)

Surge current (V)

EATON CORPORATION Eatons guide to surge suppression 23

Benefits of integrated (clipper):

FIGURE 18. INTEGRATED SPD PERFORMANCE

Some SPD manufacturers have In most cases, the original

24 EATON CORPORATION Eatons guide to surge suppression

the MOV will react 1000 times

..................................................... Let-through voltage without filter

FIGURE 20. EMI/RFI ELECTRICAL LINE NOISE

Hybrid SPDA device that Key filtering specifications:

EATON CORPORATION Eatons guide to surge suppression 25

26 EATON CORPORATION Eatons guide to surge suppression

EATON CORPORATION Eatons guide to surge suppression 27